Remove And Install Muffler
1. Remove the two bolts, from under the hood, from each of the muffler support clamps (1).
2. Lift the muffler (2) and exhaust pipe (3) straight up as a unit off the flanged exhaust outlet and until pipe clears the hole in the hood.
NOTE: The following steps are for installation of the muffler.
3. Position the muffler (2) and exhaust pipe (3) through the hole in the hood and over the flanged exhaust outlet at the engine. There is no clamp for this connection.
4. Install the bolts that hold the muffler support clamps (1) to the hood.
Remove And Install Hood
Start By:
a. remove muffler
1. Loosen clamp (1) from the radiator inlet tube (2) under the hood.
2. Remove the two mounting bolts from the hood tie angle (3) and slide the angle and clamp down the inlet tube to the engine.
3. Remove the grill (4) from the front of the machine.
NOTE: Tape the U-bolts to oil coolers at present position before hood removal to help the hole alignment when hood is reinstalled.
4. Remove the nuts from the four U-bolts (5) at the top of the oil coolers (6).
5. Remove the air cleaner support brace (7).
6. Fasten a lifting device to hood (8), remove mounting bolts (9) at front and rear of each side, and remove the hood from the machine.
NOTE: The following steps are for installation of the hood.
7. Fasten a lifting device to the hood (8) and move it into position above the cowling uprights.
NOTE: The U-bolts at the top of the oil coolers will have to be positioned vertically, and correct alignment must be made with the hood support brace mounting holes before the hood can be lowered onto the cowling uprights.
8. Position the hood mounting holes on the U-bolts (5) and with the cowling uprights. Install and tighten the hood mounting bolts (9) at front and rear for each side.
9. Install and tighten the nuts to the four U-bolts at the top of the oil coolers (6).
10. Install the grill (4).
11. Install the air cleaner support brace (7) back to the hood.
12. Slide the hood tie angle (3) and clamp up the inlet tube into position at the hood support. Install the mounting bolts and tighten the clamp (1) to the radiator inlet tube.
End By:
a. install muffler
Remove And Install Hydraulic And Lubrication System Oil Coolers
1. Remove the ground drive pump cover.
2. Remove the six mounting bolts and remove the grill (1).
NOTE: Tape the U-bolts to oil cooler at present position to help with alignment of holes when oil cooler is reinstalled.
3. Remove the nuts from the two U-bolts (2) at the top of hydraulic oil cooler (3).
4. Remove the hydraulic lines (4) at the bottom of the hydraulic oil cooler, and immediately cap or plug the openings.
5. Remove the nuts from the two U-bolts (5) at the bottom of the oil cooler.
6. Support the oil cooler at the bottom and remove U-bolts (5) from oil cooler support plate (6).
7. Lower the oil cooler until U-bolts (2) are free of top support, and then remove the oil cooler out the front of the machine.
8. Repeat steps 2 thru 7 to remove the lubrication system oil cooler.
NOTE: The following steps are for installation of the oil coolers.
9. Lift hydraulic oil cooler (3) into position behind the lower oil cooler support plate (6).
10. Put the two U-bolts (2) in the top support bar of the oil cooler, hold them in a vertical position and align with holes in hood support brace. Install the nuts on the U-bolts but leave loose for oil cooler movement.
11. Position the two U-bolts (5) over the bottom support bar of the oil cooler and through the holes of oil cooler support plate (6). Install and tighten the nuts.
12. Now tighten the nuts for the top U-bolts (2).
13. Remove the caps or plugs and install the hydraulic lines (4) to the bottom of the oil cooler.
14. Repeat steps 9 thru 13 to install the lubrication system oil cooler.
15. Put the grill (1) into position and install the six mounting bolts.
16. Install ground drive pump cover to the front of the machine.
Remove And Install Radiator
Start By:
a. remove hood
b. remove oil coolers
1. Drain the coolant from the radiator.
2. Loosen one radiator inlet tube hose clamp (1) at the radiator end and one hose clamp (2) at the engine end, and remove inlet tube (3).
3. Repeat this procedure for the radiator outlet tube (4) at the bottom of the radiator, and remove the outlet tube.
4. Remove the bolts (5) at the center of the fan guard (6).
5. Remove the mounting bolts (7) at the side of one of the fan guards and remove the guard. Remove the other guard the same way.
6. Fasten a lifting device to the radiator, and remove the five radiator mounting bolts (8) from the cowling (9) on each side.
7. Remove the radiator by moving it forward enough to clear the fan, then lifting it straight up from between the cowling uprights.
NOTE: The following steps are for installation of the radiator.
8. Position the radiator between the cowling uprights and align it with the fan and the mounting holes. Install the mounting bolts (8).
9. Install both fan guards (6) to the radiator. Be sure to install the bolts (5) at the center of the guards.
10. Put radiator outlet tube (4) into position on the bottom of radiator tube, then install other end to bottom of water pump. Tighten the hose clamps.
11. Install the radiator inlet tube (3) between the radiator and engine, and tighten the hose clamps (1) and (2).
12. Fill the radiator with coolant and check for any leaks at the hose connections.
End By:
a. install oil coolers
b. install hood
Remove Engine
Start By:
a. remove muffler
b. remove hood
c. remove oil coolers
d. remove radiator
e. remove rotor drive clutch (PTO) *
*This operation is in the RR-250 and SS-250 Vehicle Systems Disassembly and Assembly module, Form No. KEBR1243.
1. Disconnect the battery cable clamp from the positive terminal post on the battery.
NOTE: Before removal or disconnection, all electrical wires must be marked for identification at assembly.
2. Disconnect the battery cables from the starter solenoid (1) and the starter motor (2).
3. Disconnect the engine wiring harness wires (3) from the starter solenoid.
4. Disconnect the engine wiring harness wires (4) from the starter motor.
5. Disconnect the engine wiring harness wires (5) from the magnetic solenoid (6).
6. Disconnect the wire from the oil temperature sender on side of the engine oil pan (below the magnetic solenoid).
7. Disconnect each wire from the oil pressure sender (7) and oil pressure switch (8) on the side of engine block.
8. Disconnect the wire from coolant temperature sender (9) on the top of engine head.
9. Disconnect the engine harness wire from fuel solenoid (10).
10. Disconnect the two wires of engine harness from the alternator (11).
11. Disconnect the fuel lines (12) from fuel manifold block (13) and immediately plug or cap the openings.
12. Unbolt the fuel filter (14) from the engine block and move the filter and fuel lines out of the way.
13. Remove the two mounting bolts (15) from the auxiliary hydraulic pump (16) and lay the pump and its hydraulic lines out of the way on the platform.
NOTE: If rotor clutch (PTO) is to stay with the engine during engine removal, be sure to disconnect the wire from the neutral switch located near the bottom of clutch lever.
14. Cut all of the tie wraps that hold engine wiring harness to any engine component and remove or move the engine wiring harness away enough to clear the engine during removal.
15. Remove the U-bolt (17) that supports the bottom air inlet tube to the rear cowling upright.
16. Remove one hose clamp from each of the hump hoses (18), and remove both hump hoses, elbows and tubes as a unit from turbocharger (19) and air cleaner (20). Cover openings of the turbocharger and air cleaner.
17. Remove the support brace (21) located between the fenders.
18. Fasten a lifting device to the front and rear lifting brackets (22) at the top of the engine.
19. Remove the four frame mounting bolts (23) from each rear support bracket (24) under the flywheel housing.
20. Remove the two bolts (25) from the engine front support bracket (26).
NOTE: Make a final check to be sure all removals and disconnections have been made from the engine.
| NOTICE |
|---|
Shims are used between the rear engine supports and the machine frame to eliminate any twisting of engine as bolts are tightened. Make sure all shim thickness and positions are identified for engine reinstallation. |
21. Carefully lift the engine out of the frame and move it away from the machine. Make sure all lines and wiring are out of the way and are not snagged during engine removal.
Install Engine
1. Make sure all lines and wiring are out of the way, and carefully position the engine support brackets on the frame. A large punch or a pointed prybar can be used to help align the mounting holes.
2. Insert the two front support bracket mounting bolts (1) through the front support and frame holes and install the nuts and lockwashers, but do not tighten.
3. If shims were found during engine removal, position the shims between frame and support brackets exactly as originally found.
4. Insert the mounting bolts (2) through the holes of frame, shims and rear support and install the nuts and lockwashers. Tighten the nuts and bolts.
5. Tighten the nuts and bolts of the front support.
6. Install the support brace (3) back between the fenders.
7. Remove the covers from turbocharger and air cleaner, and install hump hose and piping assembly between turbocharger and air cleaner.
8. Install U-bolt (4) that supports the pipe to the rear cowling upright and tighten the hose clamp (5) at each hump hose.
9. Slip the engine wiring harness onto the engine using the same harness supports it was removed from, and connect wire to coolant temperature sender (6) at top of cylinder head.
10. Connect the wire to fuel solenoid (7).
11. Connect the wires to the alternator (8).
12. Remove the caps or plugs and connect the fuel lines (9) to fuel manifold block (10).
13. Install the fuel filter (11) to the engine block.
14. Lift the auxiliary hydraulic pump (12) into position, align the spline and push pump into place on engine accessory drive cover. Install the two mounting bolts (13).
15. Connect the wires to the oil pressure switch (14) and oil pressure sender (15).
16. Connect the wire to the oil temperature sender on the side of the engine oil pan (located below the starter motor).
17. Connect the wires to the magnetic solenoid (16).
18. Connect the harness wires and the battery cable to the starter motor (17).
19. Connect the harness wires and the battery cable to the starter solenoid (18).
20. Connect the battery cable clamp to the positive terminal post on the battery.
21. Add tie wraps as necessary to the wiring harness to make sure harness remains out of the way of engine components.
End By:
a. install rotor drive clutch (PTO) *
b. install radiator
c. install hydraulic oil coolers
d. install hood
e. install muffler
*This operation is in the RR-250 and SS-250 Vehicle Systems Disassembly and Assembly module, Form No. KEBR1243.
Remove And Install Air Cleaner
1. Loosen hump hose clamp (1) and bottom elbow clamp (2).
2. Pull the hump hose off the air cleaner (3), allowing air inlet pipe assembly (4) to rotate away from the air cleaner.
3. Remove the support strap (5) from between the vehicle hood and air cleaner body.
4. Fasten a lifting device to the air cleaner mounting brackets and remove the two bolts (6).
5. Remove the two nuts (7) from the precleaner support.
6. Lift the air cleaner (3) and the precleaner (8) away as a unit.
7. To separate the precleaner from the air cleaner, mark the relative positions of the two bodies and remove clamp (9).
NOTE: The following steps are for installation of the air cleaner.
8. If the precleaner (8) was separated from air cleaner (3), align marks and install clamp (9).
9. Lift the complete unit into position and install the nuts (7) to the the precleaner support.
10. Install the bolts (6) that support the air cleaner.
11. Install the support strap (5) to the air cleaner body and the vehicle hood.
12. Rotate the air inlet pipe assembly (4) to the air cleaner and push the hump hose onto the air cleaner opening.
13. Tighten the hump hose clamp (1) and the bottom elbow clamp (2).